U.S. patent application number 10/923644 was filed with the patent office on 2006-02-23 for wrap around carton packaging machine.
Invention is credited to Brenton L. Smith.
Application Number | 20060037290 10/923644 |
Document ID | / |
Family ID | 35908352 |
Filed Date | 2006-02-23 |
United States Patent
Application |
20060037290 |
Kind Code |
A1 |
Smith; Brenton L. |
February 23, 2006 |
Wrap around carton packaging machine
Abstract
A packaging apparatus for wrapping a carton around a packaged
product comprises a box mandrel conveyor including a plurality of
mandrels which support the packaged product thereon. Packages are
precisely fed to the mandrels of the box mandrel conveyor by a
conditioning conveyor. Carton blanks are delivered to a conveying
system for a carton magazine and are conveyed in vertical
confronting relation to a mandrel. Each mandrel moves the carton
blank against a large radius plows device thereby causing the
carton blank to be folded around a mandrel containing a package.
Folding and compression devices are provided for folding and
compressing an end panel against a manufacturer's flap. Suitable
flap closing means close the end flaps and upper and lower flaps
after the mandrel is withdrawn from the carton.
Inventors: |
Smith; Brenton L.;
(Alexandria, MN) |
Correspondence
Address: |
Herman H. Bains
6101 Tracy Avenue
Minneapolis
MN
55436
US
|
Family ID: |
35908352 |
Appl. No.: |
10/923644 |
Filed: |
August 23, 2004 |
Current U.S.
Class: |
53/566 |
Current CPC
Class: |
B65B 43/10 20130101;
B65B 11/10 20130101; B65B 5/04 20130101; B65B 49/12 20130101 |
Class at
Publication: |
053/566 |
International
Class: |
B65B 43/24 20060101
B65B043/24 |
Claims
1. Apparatus for continuously folding, forming and sealing carton
blanks around product comprising an elongate box mandrel conveyor
including a plurality of spaced apart horizontally disposed
mandrels for containing product, power means connected to the box
mandrel conveyor for moving the mandrels in a predetermined path of
travel from an upstream end to a downstream end, said mandrels
being movable transversely of the path of travel between an
advanced package supporting position and a retracted position,
means for causing movement between advanced and retracted
positions, power means connected to the mandrel conveyor for moving
the mandrel conveyor, means continuously conveying vertically
disposed carton blanks one at a time to the box mandrel conveyor in
confronting relation with a mandrel during movement of the mandrel,
each carton blank including side panels, end panels, end flaps,
upper and lower flaps, and a manufacturer's flap, the
manufacturer's flap defining the lower edge portion of a carton
blank, and notches between certain flaps and panels, means engaging
and folding the manufacturer's flap against the mandrel during
movement of the blank to the mandrel conveyor, a folding plow
device positioned downstream of the carton blank magazine for
folding a carton blank moved by a mandrel around a mandrel
containing product as the mandrel is moved in the path of travel, a
rotary flap tucker device folding a panel against the
manufacturer's flap including plates for engaging and folding the
flap and panel, and an elongate hold down rail positioned adjacent
the plow device and having a front end mounted for vertical pivotal
movement, said rail engaging and holding the blank in position for
tucking, and pivoting upwardly in response to a blank or product
projecting upwardly beyond the associated mandrel, and a sensor
mounted downstream end producing a signal in response to upward
pivoting movement at the rail to indicate an unacceptable
product.
2. The apparatus as defined in claim 1 wherein the mandrel conveyor
includes a plurality of conveyor elements, means mounting the
mandrels on the conveyor elements to permit ready placement of one
size mandrel for another size mandrel.
3. The apparatus as defined in claim 1 wherein said power means
comprises a precision electrically controlled motion generating
device (PECMGD).
4. The apparatus as defined in claim 3 wherein the PECMGD is a
servomotor.
5. The apparatus as defined in claim 1 wherein each mandrel has a
blank positioning and containment guide plate secured thereto, said
guide plate engaging a notch in the blank for maintaining proper
position of the blank as it folded around the mandrel by the
folding plow device.
6. The apparatus as defined in claim 1 and an adjustable blank
guide element mounted adjacent the mandrel conveyor and engaging a
notch in the blank during movement of each mandrel and blank in
downstream direction for maintaining the blank in proper position
for folding by the folding plow device.
7. The apparatus as defined in claim 1 and a rotary compression
device including compression plates and rotary driven member, each
compression plate being pivotally mounted on the driven member,
each compression plate engaging an compressing two blank flaps
against each and against a mandrel as the latter moves downstream,
the pivotal connection of each compression plate permitting precise
alignment of each plate with the associated mandrel, and a
precision electrically controlled motion generating device
connected to the rotary compression device and designed and
programmed to monitor and vary the compression force, and to
automatically adjust position so that a uniform and consistent
force is applied regardless of angle or position of mandrel engaged
by a compression plate.
8. An apparatus for continuously folding, forming and compressing a
blank around a product, comprising a mandrel conveyor including a
plurality of similar mandrels, for containing a product, power
means for moving the mandrel from an upstream end to a downstream
end, a magazine containing a supply of vertically disposed blanks
and having a discharge end, toothed conveyor means engaging bottom
edges of the blanks for moving the blanks to the discharge end,
means receiving blanks from the magazine and continuously conveying
vertically disposed blanks one at a time to the mandrel conveyor in
confronting relation with a mandrel during movement of the mandrel,
each blank being scored and cut to define a plurality of panels and
flaps, the lower most flap comprising a manufacturer's flap, means
engaging and folding the manufacturer's flap 180.degree. against a
mandrel as the blank is conveyed to the mandrel conveyor, means for
applying glue to the exterior surface of the manufacturer's flap of
a blank as the blank is conveyed to mandrel conveyor, the
manufacturer's flap upon release from the folding means forming an
angle of approximately 90.degree. with respect to the blank.
9. The apparatus as defined in claim 8 wherein the means for
conveying the blanks to the mandrel conveyor includes a conveyor
and nip roller assembly including a belt conveyor, a driven nip
roller having a flat surface portion disposed in opposed relation
with the belt conveyor and cooperating therewith to convey each
blank in a vertically square position with respect to the mandrel
conveyor.
10. The apparatus as defined in claim 8 and a finger drive belt
assembly positioned above the blanks and including a driven belt
having a plurality of flexible fingers secured thereto, means for
driving the belt assembly at speed slightly faster than the speed
at which the blanks are conveyed to the discharge end, said
flexible fingers engaging the top edges of the blanks and flexing
in response to the engagement to impart a resistive force to the
blanks to insure proper positioning of the blanks as each blank is
removed form the magazine.
11. The apparatus as defined in claim 8 wherein the nip roller is
shiftable between a blank engaging position and an open position,
said nip roller being shiftable away from the belt conveyer when in
the open position to enable clearing of jammed blanks
therefrom.
12. The apparatus as defined in claim 8 wherein the discharge end
of the magazine has a picking side where blanks are picked and
moved laterally from the magazine, and an opposed side, a plate
pivotally mounted on the opposed side engaging the forward most
blank to properly position each blank for proper picking and
removal from the magazine, means engaging and yieldable urging the
plate against a blank.
13. The apparatus as defined in claim 8 and upper and lower air
jets positioned above and below the magazine and connected to a
source of air under pressure and discharged compressed air into the
blanks adjacent the discharge end of the magazine.
14. A packaging apparatus for forming a blank into a carton around
a product, an elongate mandrel conveyor including a plurality of
mandrels for containing and conveying product, power means for
moving the mandrel conveyor in a predetermined path of travel from
an upstream end to a downstream end, a conditioning conveyor system
positioned upstream of the mandrel conveyor for receiving product
delivered to the conditioning conveyor system, and positioning,
compressing and precisely dropping product sequentially into
mandrels, said conditioning conveyor including an elongate table
having elongate longitudinally extending slots therein and
receiving product delivered thereto, said conditioning conveyor
including horizontally disposed endless conveyor members having a
plurality of fingered flights secured thereto, the lower run of the
conveyor members moving in a downstream direction, each flight
having fingers secured thereto and underlying and supporting
product as the product is moved by the flights, second horizontally
disposed endless conveyor members each having a plurality of
compression flights secured thereto, each compression flight
cooperating with a fingered flight to first compress a product and
thereafter precisely drop a product into mandrel as the product is
moved downstream.
15. The apparatus as defined in claim 14 and a pair of precision
electrically controlled motion generating devices each being
operatively connected to one of the finger flight conveyor members
or the compression flight conveyor members to programmatically vary
the distance between fingered and compression flight, and to
precisely and quickly control the force for driving the flights
16. A packaging apparatus for forming a blank into a carton around
a product, an elongate mandrel conveyor including a plurality of
mandrels for containing and conveying product, means for moving the
mandrel conveyor from an upstream end to a downstream end, means
for folding and sealing a blank into a sleeve around a mandrel
containing product, the blank sleeve having a pair of upper and
lower flaps, and a pair of end flaps at each end, a transfer
conveyor receiving sleeve shaped blanks containing product from the
mandrel conveyor and continuing movement thereof in a downstream
direction, the transfer conveyor including spaced apart trailing
flights engaging only the upstream end of the sleeve shaped blank,
a pair of rotary end flap tucker wheels positioned on opposite
sides of the transfer conveyor engaging and folding the end flaps
during movement of the transfer flight, plow means positioned on
opposite sides of the transfer conveyor downstream of the end flap
tucker wheels engaging and folding the upper and flaps against the
associated end flaps at each end of the sleeve to close and form
the sleeve into a carton containing a product.
17. The apparatus as defined in claim 16 wherein each tucker wheel
has a lobe projecting therefrom for engaging and tucking the
product into a sleeve shaped blank.
18. The apparatus as defined in claim 16 and means engaging the
downstream end of the carton to cause the carton to be positioned
squarely against a tracking flight.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a packaging machine and more
particularly to a packaging machine which wraps and forms a carton
around a package.
BACKGROUND OF THE INVENTION
[0002] In some conventional packaging machines, product is loaded
into preformed cartons and the cartons are subsequently closed and
sealed. Various kinds of products including dry product, bagged
flexible products, rigid products, single and multiples of bagged
and single products are loaded into preformed cartons by some
packaging machines. Typically the product is loaded (pushed)
through an open end of the carton.
[0003] When the product is a bagged flexible product such as
cereal, it is difficult at best to push the bagged product into the
carton. It will be appreciated that a cereal package, for example,
does not maintain structural integrity when subjected to pressure
(loading). Further, preformed cartons are more expensive to buy,
more difficult to handle, and more difficult to open and load
reliable.
[0004] Certain prior art efforts have resulted in the formation of
cartons wrapped around the product by packaging machines. For
example, U.S. Pat. No. 4,308,020 discloses a wrap around packaging
machine for forming a carton around a bottle such that the walls of
the carton engage the circumferential surface of the bottle.
However, few systems were manufactured. The novel devices
incorporated into this patent address the weaknesses of prior art
efforts and bring to bear processes, motions, and controls never
before seen. Specifically the Langen patent does not address the
problems of flexible packages, reliable manufactures flap closing
and sealing, glue contamination, and precise machine performance
needed for efficient packaging.
SUMMARY OF THE INVENTION
[0005] An object of this invention is to provide a novel and
improved cartoning machine in which carton blanks are partially and
precisely formed around product and thereafter the flaps are
precisely closed and sealed.
[0006] Another object of this invention is to provide a unique feed
system for the cartoning machine wherein bagged flexible products
are compressed for sizing and precisely dropped downwardly upon a
mandrel or bucket conveyor for movement to the next station.
[0007] In carrying out the invention, the product is delivered to
an infeed system which includes smart belts that constantly senses
the presence of product and moves the product to known or
predetermined positions. The product to be packaged may be flexible
products, rigid products and single and multiple bagged and single
products. The carton can be two dimensional or three dimensional in
a three, four or six-sided container with open or closed ends. The
wrap around carton may be formed of paper, paperboard corrugated
paper, microflute corrugated paper or a polymer. In the embodiment
shown, the product to be cartoned is a flexible package containing
cereal.
[0008] The product is delivered from the infeed conveyor system to
a fan feed device where product is timed delivered to a timing
conveyor. Product is then delivered to a conditioning conveyor
which drops the product into a mandrel or bucket. The conditioning
conveyor is provided with flights which compress semirigid product
(cereal packages) into a size slightly smaller than the bucket.
Fingers on the flights support the product at the discharge end of
the conditioning conveyor and prevent premature dropping of the
product into the associated bucket.
[0009] A magazine section is provided and contains blanks which are
die cut. The blanks may be coated, uncoated or laminated stock. The
blanks are delivered one at a time into the machine and during this
movement a small flap (typically called the manufacturer's joint)
is folded 180.degree. back upon the body of the carton and crimped.
A process glue is applied to the outside surface of this flap and
thereafter the flap is allowed to spring back. This adjustable
crimping force is set so that the flap spring back forms a angle of
approximately 90.degree. with the carton body. The manufacturer's
flap is properly conditioned for sealing the mating flap
downstream.
[0010] Prior art systems apply glue to the inside of the carton
flap or panel. One of the drawbacks to this prior art practice is
that it allows glue to get on the buckets if a blank feeding
problem occurs or if a missed tuck is experienced. When glue is
inadvertently applied to a bucket, then the bucket can not be
pulled from the carton and the system jams.
[0011] The blanks are folded around the packages in the mandrels by
large radius folding plows as the mandrels are moved downstream.
Positioning guide elements engage the edge portions of the blank to
assure proper positioning of the blank for folding around the
mandrel. Self-aligning flights assures accurate gluing of the
manufacturer's joint.
[0012] Uniquely designed tuckers assure proper folding of the end
flaps. The loaded and sealed carton is discharged to a case
packer.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0013] FIG. 1 is a diagrammatic plan view of the novel packaging
apparatus;
[0014] FIG. 2 is a diagrammatic side elevation view taken along
line 2-2 of FIG. 1 and looking in the direction of the arrows;
[0015] FIG. 3 is an elevational taken along line 3-3 of FIG. 2 and
looking in the direction of the arrows;
[0016] FIG. 4 diagrammatic cross-sectional view taken approximately
along line 4-4 of FIG. 1 looking in the direction of the arrow and
illustrating operation of the flap tucker device and the
compression device;
[0017] FIG. 4A is a cross-sectional view taken approximately along
line A-A of FIG. 4 and looking in the direction of the arrows;
[0018] FIG. 4B is a cross-sectional view taken approximately along
line B-B of FIG. 4 and looking in the direction of the arrows;
[0019] FIG. 4C is a cross-sectional view taken approximately along
line C-C of FIG. 4 and looking in the direction of the arrows;
[0020] FIG. 4D is a cross-sectional view taken approximately along
line D-D of FIG. 4 and looking in the direction of the arrows;
[0021] FIG. 5 is a cross-sectional view taken approximately along
line 5-5 of FIG. 1 and looking in the direction of the arrows;
[0022] FIG. 5A is an elevational view taken approximately along
line A-A of FIG. 5 and looking in the direction of the arrows;
[0023] FIG. 5B is a cross-sectional view taken approximately along
line B-B of FIG. 5 and looking in the direction of the arrows;
[0024] FIG. 5C is a cross-sectional view taken approximately along
C-C of FIG. 5A and looking in the direction of the arrows;
[0025] FIG. 6 is a fragmentary perspective view of a portion of the
apparatus, exploded, to show details of construction;
[0026] FIG. 7 is a partial front elevational view showing a carton
blank and showing adjacent portions of the apparatus in
section;
[0027] FIG. 8 is a side elevational view of the apparatus located
immediately downstream of that portion of the apparatus shown in
FIG. 1;
[0028] FIG. 8A is a cross-sectional view taken approximately along
line 8A-8A of FIG. 8 and looking in the direction of the
arrows;
[0029] FIG. 8B, FIG. 8C, and FIG. 8D illustrates the sequential
steps and mechanism for progressively folding the dust flaps;
[0030] FIG. 9 is a diagrammatic side elevational view illustrating
the slightly unsymmetrical configuration of a carton prior to
engaging the carton shaping means;
[0031] FIG. 10 is diagrammatic view similar to FIG. 9 and
illustrating the symmetrical configuration of the carton after the
carton is engaged by the carton shaping means; and
[0032] FIG. 11 is a partial diagrammatic perspective view of a
portion of the magazine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Referring now to the drawings, and more particularly to FIG.
1, it will be seen that the novel wrap around packaging apparatus
or machine 10 is thereshown. The wrap around apparatus wraps the
carton blank around a product rather than inserting the product
into a preformed carton. In the embodiment shown, the product is
cereal although the novel wrap around packaging apparatus may be
used to carton other types of product.
[0034] As used herein, the term blank refers to a single piece of
packaging material that has been shaped, sized and scored in
preparation for use in a packaging process. Various components of
the apparatus are driven by precision electrically controlled
motion generating devices (PECMGD). Three common types of PECMGD
are servomotors, stepper motors, and variable frequency drive
motors (VFD). There are also other types of PECMGD but servomotors
and VFD motors are preferred in the embodiment shown.
[0035] The term mandrel as used herein comprises a rigid structure
that serves as a conveying element when attached to a conveyor for
conveying a product. The mandrel also provides the necessary
uniform structural integrity for wrapping a blank around the
mandrel and for compressing the flaps of the blank against surfaces
of the mandrel.
[0036] The apparatus includes an infeed system 11 which receives
the product P from a table top conveyor 12. It is pointed out that
table top conveyors 12 or other types of conveyors are provided by
the packager and are not, per se, part of the packaging infeed
system. The product P is discharged from the tabletop conveyor 12
upon a metering and phasing conveyor 13 which is driven by a
servomotor 14. In the embodiment shown, all of the various
components of the apparatus are driven by servomotors which are
controlled by a computer. A suitable software program controls the
sequencing (operational speeds and timing) of the various
components.
[0037] The metering and phasing conveyor 13 operates at
approximately 100 ft./min. and discharges the packages P upon a
launch conveyor 15 which is driven by a servomotor 16. The metering
and phasing conveyor is a "smart" conveyor and is provided with
sensors (not shown) which monitors the product being conveyed. The
launch conveyor operates at approximately 400 ft./min. The packages
are impelled or launched from the launch conveyor 15 to a fan
device 17. The fan device 17 is comprised of two bladed fans 18
each including three blades 29 secured to a hub or axle 20. The hub
or axle 20 for each fan is secured to the output shaft of a
servomotor 21. In the embodiment shown each fan is driven by a
separate servomotor 21.
[0038] The blades 19 for each fan are angularly spaced apart
120.degree. and the two servomotors 21 operate at the same speed
which rotates the fans 18 at 120.degree./sec. A pair of circular
impact plates 22 are each secured to one of the axles 20 and are
located adjacent the associated servomotor 21. With this
arrangement, each package P will be launched or impelled from the
discharge end of the launch conveyor 15 against the impact plates
22 and fall upon a pair of rotating fan blades 19. When the
packaged product P strikes the impact plates 22 at the launch
velocity (400 ft./min.), this collision serves to compress the
product. It will be seen in FIGS. 2 and 3 that each product is
delivered to the fan device 17 from the launch conveyor 15 and is
then deposited by the fan device on a timing conveyor 23.
[0039] The timing conveyor 23 includes a horizontal table 24
positioned below the fan feed device 17 for receiving the products
P thereon. The products P are oriented longitudinally along the
infeed conveyor system, i.e., the sealed ends are arranged in the
direction travel. It will be noted that the products P are
delivered by the fan feed device such that the products extend
transversely of the direction of travel of the timing conveyor. The
fan feed device 17 times the delivery (120 ft./sec.) of the product
to the timing conveyor 23.
[0040] The timing conveyor 23 also includes a pair of endless
conveyor chains 25 each trained about an upstream sprocket 26 and a
downstream sprocket 27. Conveyor flights 28 extend transversely
between and are secured to the conveyor chains 25. It will be seen
in FIG. 3 that in their lower underpassing run, the flights engage
the packages and move the packages downstream to a fingered launch
conveyor 29.
[0041] The timing conveyor 23 moves the products P at approximately
200 ft./min. while the fingered launch conveyor runs at
approximately 300 ft./min. The fingered launch conveyor 29 is
comprised of a plurality of laterally spaced apart narrow conveyor
belts trained about upstream pulleys 31 and downstream pulleys 32.
It will be noted that the fingered launch conveyor is horizontally
disposed and is positioned just downstream of the discharge end of
the table 24. Products P are moved by the flights 28 downstream to
the fingered launch conveyor.
[0042] The timing conveyor 23 and the fingered launch conveyor 29
are both driven by a servomotor 33. The output shaft 34 of the
servomotor 33 has one end journaled in a suitable bearing and has a
sprocket 35 keyed thereon. A chain 37 is trained about sprocket 35
and a smaller driven sprocket 36 keyed to the shaft 38 of
downstream sprocket 27 of the timing conveyor 23. The timing
conveyor 23, in the embodiment shown, operates 200 ft./min. All of
the conveyor speeds and speeds or velocities of other components
are only for the specific packaging function disclosed and are not
intended as a limiting requirement.
[0043] A sprocket 39 is keyed to shaft 38 of the timing conveyor 23
and is drivingly connected to a sprocket 40 by a chain 41. It will
be noted that the sprocket 39 is larger than the drive sprocket 40.
The shaft 40a mounting sprocket 40 also has a larger sprocket 42
keyed thereto. A chain 44 is trained about sprocket 42 and a
smaller driven sprocket 43 which is keyed to the driven shaft 45
for the downstream sprocket 32 of the fingered launch conveyor 29.
The fingered launch conveyor 29 is operated at a velocity of 300
ft./min. in the embodiment shown. It will be noted that the
relative operational speeds of the timing conveyor and fingered
launch conveyor are not only determined by the servomotor 33 but
also the particular construction and arrangement of the sprocket
drive train.
[0044] The fingered launch conveyor 29 consists of a plurality of
spaced apart belts 30 trained about the sprockets 31, 32 and the
launch conveyor delivers the products P to the conditioning
conveyor 46. The conditioning conveyor 46 includes a flat slatted
table 47 wherein the slats 49 correspond in number and width to the
belts of the fingered launch conveyor 29. Products P are delivered
to the conditioning conveyor by the fingered launch conveyor and
are supported on the slatted table 47. The upstream ends of the
slats 49 are down turned, as best seen in FIG. 3, to facilitate the
transfer.
[0045] The conditioning conveyor 46 also includes means for moving,
compressing and precisely dropping the compressed packages into the
mandrels where the blanks are wrapped around, folded and glued to
encase the packages. A pair of laterally spaced apart, endless
chains 50 are each trained about one of a pair of drive sprockets
51 keyed to the output shaft 34 of the servomotor 33. The chains 50
are also trained about a pair of idler sprockets 52 journaled on
the output shaft 53 of a servomotor 54.
[0046] The chains 50 have a plurality of finger flights 55
pivotally secured thereto by pivots 55a. Each flight 55 has a
plurality of fingers 56 projecting therefrom. These fingers 56 are
horizontally disposed during their lower run as shown in FIG. 3 and
extend in an upstream direction. The fingers 56 pass between
adjacent slats 49 of the slatted table 47 and underlie the leading
edge portion of product P as best seen in FIG. 3.
[0047] Each finger flight includes a pair of mounting brackets 56a
having a plate 56b interconnecting the brackets 56. The fingers 56
are secured to a flange on the plate 56b. The plate 56b for each
finger flight is engaged by the leading surface of a package P as
clearly shown in FIG. 3.
[0048] The conditioning conveyor 46 also includes a pair of endless
chains 57 which are laterally spaced apart and are trained about a
pair of drive sprockets 58 keyed to the output shaft 53 of the
servomotor 54. The chains 57 are also trained about a pair of idler
sprockets 59 journaled on the output shaft 34 of the servomotor 33.
The chains 57 have a plurality of compression flights 60 pivoted
secured thereto by pivots 60a. Each flight includes a pair of
mounting brackets 62 each pivoted to an associated chain. A
compression plate 61 extends between and is secured to the
brackets.
[0049] It will be seen that the conditioning conveyor 46 is
operable to move products downstream to the bucket or mandrel
conveyor 63. As products P are moved downstream (FIG. 3), each
product will be compressed between a plate 56b of a finger flight
55 and a compression plate 61 of a compression flight 60. Products
P are compressed to reduced the transverse dimension of each
package sufficiently so that the transverse dimension of each
package is slightly less than the corresponding dimension of a
mandrel 64.
[0050] As products reach the end of the slatted table, the fingers
of a finger flight 55 will support each package as the package
moves beyond the table. The mandrel conveyor 63 operates at
approximately 150 ft./min., the same operational speed as the
conditioning conveyor. The movement of products P by the
conditioning conveyor 46 is synchronized with the mandrel conveyor
such that when each product P is released from the conditioning
conveyor the package will precisely drop into a mandrel 64.
Specifically, each product will be held between a compression
flight and a finger flight as the product moves downstream of the
end of the slatted table. The fingers support the leading edge of
each product against tilting, and the fingers of a flight move
quickly away from the supported package as flight changes direction
traveling around the downstream sprockets. This allows each product
to be precisely dropped into a mandrel 64. The slatted table 47 is
longitudinally adjustable for accommodating product of different
sizes. Thus the slatted table 47 can be adjusted longitudinally in
an upstream or downstream direction.
[0051] The mandrel conveyor 64 includes a pair of endless chains 65
trained about upstream sprockets 66 and downstream sprockets (not
shown). A plurality of mandrel assemblies 67 are secured to the
chains 65 and are moved thereby. A servomotor (not shown) drives
the downstream sprockets and the mandrel conveyor at approximately
150 ft./min. Each mandrel assembly 67 includes a generally
rectangular mandrel 64 comprised of a flat bottom wall 68 and
upstanding opposed side walls 69. A transverse strap or stop 70 is
secured to the top edges of the side walls 69 adjacent the rear
edge portion thereof. It is pointed out that the front portion of
the box mandrel 64 is that end located to the left as viewed in
FIG. 6.
[0052] Referring again to FIG. 6, it will be seen that each box
mandrel 64 has a blank flap guide 71 secured to the downstream side
wall. One end of an elongate quick change mounting arm 72 is
secured to mounting plate 73 which is secured to the rear end
portion of a box mandrel 64. The other end of the mounting arm 72
projects into and is secured to mounting arm receptacle 73 which is
a component of a slide block assembly 74. A quick change spring
urged lock pin 75 is releasably locked to the mounting arm 72 by
engaging an aperture 76 in the arm.
[0053] The mounting arm receptacle 73 is secured to a flat bed
plate 77 which is secured to a pair of elongate, transversely
extending slide bearings 78. A pair of elongate, spaced apart slide
rods 79 each extends through a slide bearing 78 and the rear end of
each rod is secured to a drive chain 65 by a mounting link 80. The
front end of each rod 79 is secured in a bearing block 81 which is
affixed to the other drive chain 65. It will be seen that mandrels
64 can be readily changed for accommodating different size
products.
[0054] It will be seen that each mandrel 64 and associated slide
block assembly 74 are moved as a unit downstream but that each
mandrel 64 is moved transversely of the direction of travel between
on advanced and retracted positions. Referring again to FIG. 6, it
will be seen that an apertured spacer block 82 is secured to the
lower surface of the bed plate 77 of the slide block assembly 74.
The axle of a roller or cam follower 83 is journaled in the opening
or aperture of the spacer block 82 for rotation relative
thereto.
[0055] A pair of spaced apart cam guide tracks 84 are engaged by
the cam roller 83 of slide block assembly 74. The disposition of
the tracks 84 and the co-action of the cam roller with the tracks
produces the transverse movement of the mandrel and slide block
assembly. It will be seen that the cam guide tracks 84 change
direction from a straight run to a slightly inwardly angled run in
a downstream direction. This change in direction produces the
transverse movement of the each mandrel in a retracted direction.
The cam guide tracks 84 also change direction in the upstream
return direction (a shown in FIG. 1). This change in direction
produces the transverse movement of each mandrel in an advanced
direction.
[0056] A stripper plate 85 is secured to bearing blocks 81 of the
slide block assembly 74. The stripper plate includes a vertical
portion 85a and a horizontal portion 85b. The vertical portion has
a shaped opening 85c therein through which the associated mandrel
is moved as shown in phantom line configuration in FIG. 6. The
enlarged downstream portion of the opening 85a allows different
size mandrels 64 to be used. During the loading and carton folding
steps, each mandrel will be in the advanced position and will
project transversely through the opening 85c in the stripper plate
85 as best seen in FIG. 1.
[0057] Blanks 86 are fed sequentially into the mandrel conveyor
from a magazine 87 as shown in FIGS. 1 and 11. The blanks 86 are
vertically arranged in the magazine and are fed towards the
discharge end by toothed conveyor chains 87b which are driven by a
servomotor 87a. A follower plate 87c engages the rearmost blank 86
and moves with the conveyor chains 87b.
[0058] The discharge end of the magazine 87 as shown in FIGS. 1 and
11 has an outer side and an inner side (closest to the mandrel
conveyor) where the blanks are picked or removed one at a time. The
outer side of the magazine has a spring loaded plate 87d pivotally
mounted on the magazine housing by an elongate pivot 87e. A spring
87f urges the plate 87d against the forward most blank. The plate
vertically supports the blanks for proper picking by vacuum cups 88
which are moveable about a vertical axis to selectively remove the
blanks from the magazine. The yieldable pivotal mounting of the
plate 87d prevents blanks from binding against the plate.
[0059] The magazine also includes a plurality of fingers 87g each
pivotally mounted by a pivot 87h which engage the forward most
blank. The fingers are counterbalanced and provide light resistance
to forward movement of each blank and thereby prevent the blanks
from unduly flopping around as the blanks are removed from the
magazine.
[0060] The magazine 87 is also provided a rubber finger belt drive
assembly 89 located at the top of the magazine. The belt 89a is
provided with a plurality of rubber fingers 89b. The belt 89a is
trained about pulleys 89c, one of which is secured to the output
shaft of a servo motor 89d. The belt 89a moves at a speed slightly
greater than the speed of the blanks 86 (conveyor chains 87b). The
belt 89a moves at a speed slightly greater than the speed of the
blanks 86 (conveyor chains 87b). The fingers 89b are arranged in
groups and engage tops of the blanks as the fingers flex backward
and slide across the top surfaces of the blanks. The resistive
force applied by the rubber fingers insures that the tops of the
blanks are properly positioned up against top clip 87i.
[0061] The magazine is provided with a pair of clips 87i which are
vertically spaced apart. The top and bottom clips 87i provides
resistive force to help separate blank being picked from the one
behind it. The lower clip has a sensor assembly 87j that signals
the conveyor drive 89d when to advance the stack of blanks.
[0062] Each carton blank 86 is of conventional construction having
preformed score lines and appropriate notches. Each blank 86
includes side panels 86a and 86b, end panels 86c and 86d, end panel
flaps 86e, side panel upper and lower flaps 86g and 86h, and a
manufacturer's flap 86i. The blank 86 also as preformed notches
including notches 86j.
[0063] Referring now to FIGS. 4, 4A-4D and FIG. 7, it will be seen
that the carton blank infeed system includes a relatively short
initial belt conveyor 90 comprised of a pair of vertically spaced
apart belts 91 trained about pulleys 92 secured to a vertical shaft
93. The conveyor 90 is driven by a servomotor (not shown). The
conveyor 90 moves each carton blank inwardly where the carton blank
is engaged by a belt conveyor 94.
[0064] A nip roller shaft 93a is positioned adjacent the outer
shaft 93 of the belt conveyor 90 and a pair of nip rollers 93b are
secured to the shaft 93a. Each nip roller has a flat surface or
spot 93c. The flat surface of each roller 93b is positioned so that
the blank inserted by the vacuum cups 88 into the nip belt and
roller assembly is positioned beyond the centerline of the nip
roller shaft 93a. This feature ensures that a blank is gripped at
its top and bottom edges and pulled into the nip belt assembly so
that the blank remains square.
[0065] The nip belt and roller assembly also includes a short
conveyor 90a which cooperates with the nip rollers 93b and conveyor
belts 90 for moving a blank 86 inward to the mandrel conveyor. The
conveyor 90a also cooperates with the conveyor 94 for moving a
blank towards the mandrel conveyor. It is pointed out that the
shaft 93a and nip rollers 93b along with conveyor 90a are shiftable
as a unit away from the conveyor 90 if a jam occurs. The nip
rollers and shaft along with conveyor 90a may be returned to its
normal operating position after the jam is cleared.
[0066] The belt conveyor 94 includes a pair of vertically spaced
apart conveyor belts 95 trained about pulleys 96. The outboard
pulleys are keyed to a vertical shaft 97 while the inboard pulleys
96 are each mounted on short vertically disposed shafts 98. A
servomotor (not shown) drives both conveyors at high speeds so that
each carton is rapidly moved inwardly and are stopped by stop
plates 99 located inwardly of the conveyor 94 as shown in FIG. 4.
Each carton blank 86 will then be in position for folding.
[0067] It will be noted that the manufacturer's flap 86i is folded
and crimped as the carton blank is fed into position for folding.
The carton blank 86 will be vertically disposed as it moves to the
mandrel conveyor and the lower portion of the blank will be engaged
by a driven conveyor belt 100 and a roller assembly 101. The roller
assembly includes a mounting bar 102 having plurality of roller
axles 103 secured thereto and depending therefrom. Rollers 104 are
journaled on the axles 103. The rollers are transversely aligned
and cooperate with the belt conveyor 100 in moving and holding the
lower portion of the blank against angular movement during folding
and crimping of the manufacturer's flap 86i.
[0068] A flap folding assembly 105 is positioned adjacent the
manufacturer's flap as the blank is moved inwardly. The flap
folding assembly 105 includes a plurality a flap folding blocks 106
which are arranged in side-by-side relation and each block has a
folding surface 107. Spacer elements 106a are positioned between
adjacent folding blocks 106. The flap folding blocks are mounted on
an elongate rod 105a which is secured to a pair of brackets affixed
to a mounting plate 105b. The mounting plate 105b is secured to a
pair of mounting blocks 105c which are slidable on a pair of rods
105d. The flap folding surface 107 are arranged such that the
manufacturer's flap 86i will be progressively folded from its
vertical position located in the general plane of the blank (FIG.
4A) upwardly 180.degree. to lie against the blank (FIG. 4B) thereby
crimping a manufacturer's 86i by crimping roller 108. The crimping
roller 108 is located just inwardly of the innermost flap folding
element 106 and is mounted on the flap folding assembly 105. Glue
is applied by a glue gun 109 to the outer surface of the folded
manufacturer's flap 86i (FIG. 4C) just before the flap is released
by the crimping roller.
[0069] After the glue has been applied to the outer surface of the
manufacturer's flap 86i the blank will be moved against the stop
plates 99 releasing the flap from the crimping roller 108. The flap
86i will spring back approximately 90.degree. as shown in FIG. 4D.
The crimping roller 108 is adjustable (adjustment of the flap
folding assembly) such that the spring back of the flap is
approximately 90.degree. with respect to the carton body. By
placing the glue on the outside and by enabling the flap to spring
back to the 90.degree. position, the flap is now in position for
proper sealing downstream. Further, by applying the glue to the
outer surface of the manufacturer's flap, the likelihood of the
glue contaminating the buckets and producing jams in the system is
substantially reduced if not precluded.
[0070] Referring now to FIG. 5 and FIG. 5A-FIG. 5C, it will be seen
that the carton blank 86 begins the folding and sealing operation
around each mandrel as the mandrels move downstream specifically an
end panel 86c of a carton blank 86 is engaged by the downstream
side wall of mandrel as the latter moves downstream. The flap guide
71 on the mandrel 64 and the flap guide 71a on the frame engage in
the notches 86j of the carton blank to properly position and
maintain each carton blank for accurate folding of the carton blank
as best seen in FIG. 7. The flap guide 71a is vertically adjustable
for accommodating different size blanks.
[0071] The carton blank engages a plow device including an inclined
upper plow 110 and an inclined lower plow 111 which progressively
fold the carton against the mandrel. Each plow converges towards
the mandrel and terminates in horizontal portions 112. It will be
seen that carton will be folded, as shown in FIG. 5, with the end
panel 86d lying in the plane of the side panel 86a. It further be
noted that the manufacturer's flap 86i will remain in its
90.degree. fold (spring back position) in position for sealing with
end panel 86d. Each folding plow 110, 111 is a large radius plow
for insuring gentle handling of the blank as it is folded around a
mandrel.
[0072] A flap tucker device 113 is located above the box mandrel
conveyor and downstream of the plows 110, 111. The flap tucker
device 113 includes a frame 114 which is comprises of spaced apart
interconnected opposed plates of generally triangular
configuration. In the embodiment shown, endless chains 115 are
trained about three sprockets 116. One of the sprockets is driven
to move the chains and sprockets in a general counterclockwise
direction as viewed in FIG. 5. The chains 115 have flap engaging
plates 117 secured thereto and projecting therefrom. It will be
seen that the flap engaging plates 117 sequentially engage each end
panel 86d to fold the end panel 86d against the glue coated surface
of the manufacturer's flap 86i as the flap tucker device is
operated. In this regard the flap tucker device 113 is operated by
a servomotor (not shown). It will be noted that the flap engaging
plates have a flat surface which engages each end panel 86d. It
will also be seen that three flap engaging plates 117 are provided
although this number may vary.
[0073] An elongate rail 200 has an upwardly inclined front portion
201 which is pivoted to the frame or side plates of the apparatus
by a pivot 202. The major portion of the rail 200 engages the upper
surface of product P as product is moved past the flap tucker
device 113. The rail 200 is not contacted by the plates 117 and
extends beyond the flap tucker device 113. The downstream end of
the rail 200 has a sensor device 203 thereon which senses pivoting
movement of the rail.
[0074] If a product P is oversized or bulging, the product will
cause the rail to pivot upwardly and the sensor 203 transmits a
signal in response to this movement to inform an opoerator or other
personnel that the oversized product is to be rejected. This
sensing system prevents the occurrence of jams.
[0075] Positioned slightly downstream and in partially overlapping
relation with the flap tucker device 113 is a compression device
118 as shown in FIG. 5. The compression device 118 includes an
endless chain 119 trained about sprockets 120 each provided with a
shaft 121. One of the sprocket is driven by a servomotor (not
shown). A single servomotor may drive both the flap tucker device
113 and compression device 118 or both devices may be driven by
separate servomotors. In any event, the operational velocity or
speed of the flap tucker device 113 and compression device 118 are
synchronized with each other and with the linear speed of the box
mandrel conveyor.
[0076] Referring now to FIG. 5 and FIGS. 5A-5C it will be seen that
the compression device 118 includes a plurality of compression
flights 122 each comprised of an elongate flat compression bar 123.
Each compression bar 123 is rigidly connected to an attachment
element 124 extending at a right angle from the center portion
thereof. The attachment element has an opening 125 there through
for receiving a roll pin 126 therein. The chain 119 has a plurality
of specialized chain links 119a (one pair for each compression bar
123). Each link 119a has an opening 119b therein corresponding in
size to the opening 125. Each link 119a is connected to the next
adjacent conventional link by a pin 119d having a conventional roll
pin 119c therein.
[0077] It will be noted that the openings 119b and 125 through the
modified links 119a and attachment elements 124 are larger than the
roll pin 126. The compression bar will therefore move into self
alignment when compressing the flap 86i and end panel 86d against
the upstream side wall of a mandrel 64. This self alignment feature
enables effective compression and sealing of end panel 86d and
manufacturer's flap 86i even if the upstream vertical wall of the
mandrel is misaligned with respect to the compression flights.
[0078] The blank 86, after the compression and sealing operation,
presents an open-ended sleeve around the mandrel containing the
product. The small end flaps 86e and the large lower 86g and upper
86h flaps must now be folded and sealed. The mandrels 64 will be
sequentially retracted as shown in FIG. 1 after the mandrels have
been moved past the compression device 118. As the mandrels are
retracted, the folded cartons will be prevented from moving with
the mandrels by the stripper plates 85.
[0079] The folded cartons are transferred from the box mandrel
conveyor to a transport chain conveyor 127 which is comprised of a
pair of chains 128 which are laterally spaced apart and trained
about sprockets (not shown) and driven by a servomotor (not shown).
It is pointed out that each folded carton is dropped approximately
0.13'' from the mandrel 64 upon the chains 128 of the transport
chain conveyor.
[0080] The transport chain conveyor 127 also includes flights 129
which includes a pair of flight elements 130 each secured to a
chain. Each carton is engaged by a flight 129 as shown in FIG.
8-FIG. 10 and the cartons are moved downstream. Unlike prior art
devices, each carton is engaged by a rear flight only rather than
captured between front and rear flights. This is possible since the
wrapping of the blank around a mandrel containing a product results
in only slight deformation of the carton.
[0081] The carton will have a slightly unsymmetrical or non-squared
configuration as it leaves the box mandrel conveyor 63 as best seen
in FIG. 9. This non-squared configuration occurs as a result of the
wrap around method of applying the carton to the product. Only the
manufacturer's flap 86i is crimped or creased while the other score
lines are not creased. The flights 129 are mechanically held square
with respect to the transport chains 128. Each carton will
experience resistance from the folding plows, containment rails or
brushes and spring clips. This resistance force slides the carton
squarely against the flight as shown in FIG. 10. Since the flight
is square, the carton is square and the tucking, gluing an
compressing can now take place.
[0082] Referring again to FIG. 8, it will be seen that a hold down
brush 132 will engage an upper panel of the carton and exert a
downward force. Spring clips 133 are positioned below the chains
128. The spring clips may be formed of spring metal or may be
pivoted. In the embodiment shown, the spring clips 133 exert an
upward and rearward force on the carton. The cooperative action
between the clips 133, each brush 132 and other components cause
carton to be moved against the flight plate to square the carton as
shown in FIG. 10. One spring clip 133 is pivoted to a bracket and
urged to its upward position by a spring (not shown). The other
spring clip 133a is formed of spring metal.
[0083] The brush 132 is adjustable and includes an elongate rod 135
having opposite ends there of pivotally connected to post or
brackets 137 secured to the brush 132. An adjustment mechanism 138
is operatively connected to the downstream bracket 137. Although
not shown, the lower ends of the brackets 137 are pivoted to the
brush 132 to form a conventional parallelogram linkage. By
operating the adjustment mechanism 138 the parallelogram linkage
can be adjusted thereby slightly raising or lowing the brush
132.
[0084] Referring now to FIG. 8 and FIGS. 8A-8D, it will be seen
that means are provided for plowing and tucking the vertical end
flaps 86e. This means includes a pair of lateral spaced apart
identical rotary tucker wheels 139 positioned on opposite sides of
the transport chain conveyor 12. Each rotary tucker wheel 139 is
comprised of a pair of vertically spaced apart discs 140 rigidly
interconnected by a central spacer element 141. An annular space is
defined between each tucker disc and the peripheral edge portions
are tapered outwardly.
[0085] The rotary tucker wheels 139 are horizontal disposed for
rotation about a vertical axis. Each tucker wheel 139 is driven by
a servomotor 143 whose out put shaft 144 is connected to the
associated tucker wheel. A pair of flap holding plows 145 are
mounted on each side of the transport chain conveyor 127 just
downstream of the rotary tucker wheels 139. Each plow 145 has a
reduced end portion 146 which projects into the annular recess of
the associated rotary tucker wheel 139 as diagrammatically
illustrated in FIG. 8A and FIG. 8B. It will be seen that the
holding plows 145 are vertically disposed and that the reduced end
portions 146 diverge outwardly.
[0086] Each rotary tucker wheel 139 is provided with a lobe 147 on
its outer periphery. Each wheel 139 is also provided with a notch
in its periphery adjacent the lobe 147. The rotary tucker wheels
tuck the vertical end flaps 86e (often called dust flaps).
Referring now to FIG. 8A, it will be seen that the small end flaps
86e are positioned to be engaged the rotary tucker wheels. When the
leading end flap 86e contacts the associated rotary tucker wheel,
the wheel speed (angular velocity) is approximately equal to the
linear speed of the carton (chain conveyor). The lobes 147 will
move inside the carton and pushes the product (FIG. 8B). The
reduced end of the holding plow 145 will hold the leading end flap
down and the trailing end flap will enter the notch 148.
[0087] When the trailing end flap 86e enters the notch 148, the
rotary wheel will accelerate to approximately twice the carton
(chain conveyor) linear speed to properly tuck the end flap
forwardly. Once the trailing end flap is tucked, the wheel is
decelerated to its base speed. Since the rotary tucker wheels are
servomotor driven, the servomotors can automatically adjust and
thereby obviate the need for different size lobes. The end flaps
86e are folded to the position as shown in FIG. 8D. At this point,
the end flaps 86e are tucked and the carton squared (FIG. 10), the
carton will continue downstream through plows that fold the top
flaps 86h and the bottom flaps 86g, past glue guns, and through
side rails that apply pressure to the folded top and bottom
flaps.
[0088] Referring again to FIG. 8, it will be seen that a pair of
lower flap folding plows 149 are positioned downstream of the
rotary tucker wheels 139. The folding plows are positioned on
opposite sides of the chain conveyors 128 and each plow 149 has an
upwardly inclined edge 150 which engages a lower flap 86g and
progressively folds the flap upwardly. A glue gun 151 applies glue
(preferably hot melt) to the outer surface of the folded lower
flaps 86g.
[0089] A pair of upper flaps folding plows 152 are located
downstream of the plows 149. Each plow 152 has a downwardly
declined edge 153 which engages an upper flap 86h and progressively
folds the flap downwardly against the glue coated outer surface of
the lower flap 86g. All of the flaps are now folded and glued, and
the carton continues its downstream movement between side rails
154. The side rails are arranged to apply pressure needed to adhere
the flaps together. The sealed cartons are conveyed to a case
packer system where the cartons are packed in cases.
[0090] From the foregoing description it will be seen that the
novel packaging utilizes several unique features enabling an
efficient wrap around packaging system. All of the machine motions
in this system are controlled by (PECMGT). The use of servomotors
allows a wide range of operational conditions without requiring
much human intervention.
[0091] The present system uses low radius plows to wrap the carton
blanks around mandrels to enable gentle handling of the blanks.
This minimizes damage to the blanks and thereby decreases waste.
The manufacturer's flap is folded and creased with glue applied as
the blank is conveyed to the box mandrel conveyor. This properly
positions the folded manufacturer's flap for downstream gluing to
an end panel in forming the carton sleeve.
[0092] A unique conveying system permits conditioning and precise
feeding of the packages to the box mandrel conveyor. Rotary flap
folding wheels not on assure efficient flap folding, but these
folding wheels are constructed compress the package to provide for
good carton end flap seals.
[0093] Thus it will be seen, that a novel wrap around carton
packaging apparatus has been provided which provides advantages not
present in prior art packaging systems.
* * * * *